Stabilizer bar assembly for vehicle suspension system

ABSTRACT

A suspension system having a stabilizer bar assembly with a stabilizer bar structure, an intermediate bushing and a resilient bushing. The stabilizer bar structure includes a center section to which the intermediate bushing is coupled. The resilient bushing is mounted on the intermediate bushing. The intermediate bushing limits relative axial movement of the resilient bushing in along the center section in a first direction and a second direction opposite the first direction. A method for forming a stabilizer bar assembly is also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 11/251,369 filed on Oct. 14, 2005. The disclosure of the above application is incorporated herein by reference.

INTRODUCTION

The present invention generally relates to stabilizer bars for vehicle suspensions. More particularly, the present invention relates to a stabilizer bar mounting system that can improve both the mounting of the stabilizer bar to the vehicle frame and the lateral retention of the stabilizer bar.

Stabilizer bars, also known as sway bars or anti-roll bars, are employed in a vehicle suspension system to reduce a body roll in a vehicle during a turn. With reference to FIGS. 1 and 2, a prior art stabilizer bar can be formed of a solid or tubular material and includes a center section 110, first and second arms 112 and 114, respectively, that are coupled to the opposite ends of the center section 110, and first and second bushings 116 and 118, respectively. The first and second arms 112 and 114 can be configured to attach to left and right suspension members 120 and 122, respectively, while the first and second bushings 116 and 118 are configured to rotatably mount the center section 110 to the vehicle frame 124.

Lateral forces exerted on the stabilizer bar during the operation of the vehicle tend to push the center section 110 in an axial direction and as such, the center section 110 of prior art stabilizer bars includes first and second thrust flanges 126 and 128, respectively, that are disposed adjacent the bushings. The first and second thrust flanges 126 and 128 are employed to retain the first and second bushings 116 and 118, respectively, in a desired location. The thrust flanges 126 and 128 can be of a formed metal (upset) type collar, a plastic injection molded type collar, a crimp type collar, a multi-piece wedge type collar or a weld-type collar.

One drawback associated with this configuration is that the thrust flanges 126 and 128 must be precisely positioned so as to inhibit an undesired amount of lateral movement but yet not interfere with the rotation of the center section 110. Given normal manufacturing variation with, for example, the location of the mounting holes in the suspension component, the location of the mounting holes in the vehicle frame 124, the overall length of the center section 110, the length of the first and second arms 112 and 114, and the accuracy and repeatability with which the thrust flanges 126 and 128 may be fixedly secured to the center section 110, it can be challenging to accurately place the first and second thrust flanges 126 and 128 in a manner that provides satisfactory performance and yet may be utilized with components across the broad spectrum of manufacturing tolerances.

SUMMARY

In one form, the present teachings provide a vehicle suspension system with a stabilizer bar assembly having a bar structure, an intermediate bushing, a first bushing and a second bushing. The bar structure includes a center section and first and second arms that are disposed on opposite sides of the center section. The intermediate bushing is coupled to the center section and has a locating collar. The first and second bushings are at least partially formed of a resilient material. The first bushing is disposed over the locating collar and the second busing is mounted on the center section axially spaced apart from the first bushing. The locating collar limits movement of the first bushing along an axis of the center section in a first direction that is parallel to the axis of the center section and a second direction that is opposite the first direction.

In another form, the present teachings provide a vehicle suspension system with a stabilizer bar assembly having a bar structure, an intermediate bushing, a first bushing and a second bushing. The bar structure can include a center section and first and second arms that are disposed on opposite sides of the center section. The intermediate bushing is coupled to the center section. The first bushing is disposed over the intermediate bushing, while the second busing is mounted on the center section axially spaced apart from the first bushing. The intermediate bushing limits movement of the first bushing along an axis of the center section in a first direction that is parallel to the axis of the center section and a second direction that is opposite the first direction.

In yet another form, the present teachings provide a method for forming a stabilizer bar. The method can include: forming a bar structure with a center section; forming an intermediate bushing onto the center section, the intermediate bushing having at least one locating collar; and assembling a resilient bushing to the intermediate bushing such that the at least one collar limits relative axial movement of the resilient bushing along the center section in a first direction and a second direction opposite the first direction.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Additional advantages and features of the present invention will become apparent from the subsequent description and the appended claims, taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a portion of a vehicle with a suspension system utilizing a prior art stabilizer bar assembly;

FIG. 2 is a sectional view of a portion of the stabilizer bar of FIG. 1;

FIG. 3 is a perspective view of a portion of a vehicle with a suspension system utilizing a stabilizer bar assembly constructed in accordance with the teachings of the present invention;

FIG. 4 is a section view of a portion of the stabilizer bar of FIG. 3;

FIG. 5 is a longitudinal sectional view of a portion of a second stabilizer bar assembly constructed in accordance with the teachings of the present invention;

FIG. 6 is a longitudinal sectional view of a portion of a third stabilizer bar assembly constructed in accordance with the teachings of the present invention; and

FIG. 7 is a sectional view of a portion of a fourth stabilizer bar assembly constructed in accordance with the teachings of the present invention.

DETAILED DESCRIPTION OF THE VARIOUS EMBODIMENTS

With reference to FIG. 3 of the drawings, a suspension system 8 is illustrated to have a stabilizer bar assembly 10 that is constructed in accordance with the teachings of the present invention. In the particular example provided, the suspension system 8 is an independent front wheel suspension system of the type having upper and lower control arms and a strut assembly at each wheel that is suspended from the vehicle frame. It will be understood that the particular type of suspension system described herein and illustrated in the drawings is merely exemplary and that the teachings of the present invention have applicability to other types of suspension systems, including beam steer axles. Reference will be made to a vehicle frame in the present disclosure, but those of ordinary skill in the art will recognize that many current vehicles do not have a frame per se, but instead have regions of the body which act as an integrated frame structure. With this in mind, the frame 20 is shown to partially include a pair of longitudinally extending side rails 22 and a cross beam 24.

The suspension system 8 can include a lower control arm 26 and an upper control arm 28, both of which can be pivotally attached to the frame 20. A strut assembly having a helical coil spring 30 and a strut damper 32 can be retained between an intermediate portion of the lower control arm 26 and the frame 20 to support the weight of the vehicle and any loads which are transmitted through the lower control arm 26. The upper control arm 28 can be connected to the lower control arm 26 by a steering knuckle 34. A hub and a rotor assembly 36 can be rotatably attached to a spindle portion (not shown) of a steering knuckle 34 such that a wheel and a tire may can be mounted thereon.

With additional reference to FIG. 4, the stabilizer bar assembly 10 can include a stabilizer bar structure 40, an intermediate bushing 42 and first and second resilient bushings 44 and 46, respectively. The stabilizer bar structure 40 can include an elongated central section 50 and a pair of arm members 52 that can be disposed on opposite sides of the central section 50. The distal end 54 of each of the arm members 52 can be connected to a corresponding one of the lower control arms 26 in a conventional manner. Examples of suitable connection methods are described in U.S. Pat. No. 5,954,353 entitled “Plug In Direct Acting Stabilizer Bar Link”; U.S. Pat. No. 6,007,079 entitled “Direct Acting End Link For Stabilizer Bar”; U.S. Pat. No. 6,007,080 entitled “Plug In Direct Acting Stabilizer Bar Link”; U.S. Pat. No. 6,254,114 entitled “Composite Stabilizer Bar Link”; and U.S. Pat. No. 6,308,972 entitled “Self-Locking Plug-In Stabilizer Bar Link Mechanism”, the disclosures of which are hereby incorporated by reference as if fully set forth herein in their entirety.

The intermediate bushing 42 can include at least one locating collar 60 and can be coupled to the central section 50 at a location where the first resilient bushing 44 is to be placed. The intermediate bushing 42 can include two distinct thrust surfaces 62 that can be configured to cooperate to limit relative axial movement of the first resilient bushing 44 along the central section 50. In the particular example provided, the thrust surfaces 62 are formed on the opposite lateral surfaces of the locating collar 60. It will be appreciated, however, that the intermediate bushing 42 a may employ two or more spaced-apart locating collars 60 a as is shown in FIG. 5 to limit relative axial movement of the first resilient bushing 44 a. In this regard, each of the locating collars 60 a is employed to restrain relative axial movement of the first resilient bushing 44 a in response to the application of a thrust load against one set of thrust surfaces, e.g., the thrust surface 62 a is operable for resisting thrust loads in a first axial direction, while the thrust surface 62 b is operable for resisting thrust loads in a second axial direction opposite the first axial direction.

Returning to FIGS. 3 and 4, the intermediate bushing 42 can be formed of a plastic material, such as an injection moldable polymer, and in the example provided is molded onto the central section 50 at a desired location after the formation of one or both of the arm members 52. The polymer material is advantageous in that it can provide a smooth and consistent interface with the first resilient bushing 44.

The first resilient bushing 44 can be assembled to the central section 50 (e.g., prior to formation of the arm members 52 and the intermediate bushing 42) and pushed axially over the intermediate bushing 42 such that the first resilient bushing 44 is engaged to the at least one locating collar 60. In the example provided, the first resilient bushing 44 is received over the intermediate bushing 42 and is configured to engage the opposite thrust surfaces 62 that are formed on the locating collar 60. Accordingly, contact between the thrust surfaces 62 and corresponding surfaces 70 formed on the first resilient bushing 44 can limit relative axial movement of the first resilient bushing 44 along the central section 50.

The second resilient bushing 46 can also be assembled to the central section 50 (e.g., prior to formation of the arm members 52 and the intermediate bushing 42) and pushed into a desired location. Unlike the arrangement for the first resilient bushing 44, the second resilient bushing 46 is “free floating” and can be translated along the central section 50.

A pair of mounting brackets 74 a and 74 b can be employed to rotatably attach the central section 50 to the frame 20. The mounting brackets 74 a and 74 b are conventional in their construction and operation and need not be discussed in significant detail herein. Briefly, each of the mounting brackets 74 a and 74 b can be mounted about an associated one of the first and second resilient bushings 44 and 46 and thereafter aligned to mating holes (not specifically shown) in an appropriate structure or structure, such as the frame 20. As those of ordinary skill in the art will appreciate from this disclosure, the mounting brackets 74 a and 74 b can be mounted to any appropriate structure, including control arms, beam axles, etc., and the mounting brackets 74 a and 74 b need not be mounted to the same type of structure (i.e., both mounting brackets need not be mounted to the frame 20 but rather one could be mounted to one type of structure, such as the frame 20, and the other could be mounted to another type of structure, such as a control arm. Note that when the mounting bracket 74 b is to be aligned to the mating holes in the appropriate structure (i.e., the frame 20 in the particular example provided), the second resilient bushing 46 may be readily moved in an axial direction along the central section 50. Threaded fasteners (not specifically shown) can be employed to secure the mounting brackets 74 a and 74 b to the frame 20 or other structure. As the mounting brackets 74 a and 74 b engage the first and second resilient bushings 44 and 46, movement of the first and second resilient bushings 44 and 46 relative to the frame 20 is inhibited. Furthermore, as the thrust surfaces 62 of the locating collar 60 are disposed between the corresponding surfaces 70 formed on the first resilient bushing 44, movement of the central section 50 in an axial direction relative to the first resilient bushing 44 and the corresponding structure (i.e., the frame 20 in the example provided) is limited.

Those of ordinary skill in the art will appreciate from this disclosure that the use of an intermediate bushing permits additional functionality to be incorporated into the intermediate bushing/first resilient bushing arrangement. In the example of FIG. 6, the first resilient bushing 44 b is configured to sealingly engage the intermediate bushing 42 b at locations outboard of the locating collar 60 b so that a seal 75 is formed therebetween. Configuration in this manner is advantageous in that it inhibits ingress of contaminants, such as water, dirt and debris, between the intermediate bushing 42 b and the interior of the first resilient bushing 44 b.

In yet another embodiment, which is illustrated in FIG. 7, one or more of the interior surface 80 of the first resilient bushing 44 c, the exterior 82 of all or a portion of the intermediate bushing 42 c and the exterior surface 84 of the central section 50 c may be formed with a non-circular cross-section. In the particular example provided, the aperture 82 through of the first resilient bushing 44 c is formed such that it has hexagon-shaped cross-section, while the intermediate bushing 42 c has a correspondingly shaped hexagon-shaped cross-section. Accordingly, rotation of the central section 50 c relative to the first resilient bushing 44 c causes the first resilient bushing 44 c to act as a torsion spring.

While the intermediate bushing 42 has been described herein as being formed of plastic and molded onto the central section 50 of the stabilizer bar structure 40, those of ordinary skill in the art will appreciate that the intermediate bushing 42 may be formed in numerous other ways. For example the intermediate bushing 42 (or portions thereof) may be formed of an appropriate metal or plastic material and bonded (e.g., via an adhesive) to the central section 50, or from an appropriate metal and brazed or welded (e.g., via arc, TIG, MIG, spot/resistance, laser and/or friction/spin welding) to the central section 50, or from an appropriate metal or plastic and press-fit to the central section 50, or formed from an appropriate metal or plastic and fixedly coupled to the central section 50 via pins, threads, threaded fasteners, rivets, etc., or formed from the central section 50 in a forming operation (e.g., forging, spinning, rolling, hydroforming).

While the invention has been described in the specification and illustrated in the drawings with reference to various embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as defined in the claims. Furthermore, the mixing and matching of features, elements and/or functions between various embodiments is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that features, elements and/or functions of one embodiment may be incorporated into another embodiment as appropriate, unless described otherwise, above. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this invention, but that the invention will include any embodiments falling within the foregoing description and the appended claims. 

1. A stabilizer bar assembly comprising: a bar having a center section and first and second end sections disposed on opposite sides of said center section; a locating collar coupled to said center section at a first location; a first bushing disposed over said locating collar such that said locating collar limits bi-directional axial movement of said first bushing relative to said center section; and a second bushing disposed for axially sliding movement on said center section relative to said first bushing toward a second location.
 2. The stabilizer bar assembly of claim 1 wherein said locating collar is fixed to said center section at said first location and has first and second thrust surfaces, and wherein said first bushing surrounds said locating collar such that said first thrust surface inhibits axial movement of said first bushing in a first direction along said center section and said second thrust surface inhibits axial movement of said first bushing in a second direction along said center section.
 3. The stabilizer bar assembly of claim 2 wherein said first bushing encloses said locating collar and has an inner surface engaging an outer surface of said center section.
 4. The stabilizer bar assembly of claim 2 wherein said locating collar is molded onto said center section of said bar.
 5. The stabilizer bar assembly of claim 1 wherein said locating collar extends outwardly from a tubular member that is coupled to said center section at said first position, and wherein said first bushing surrounds said tubular member.
 6. The stabilizer bar assembly of claim 5 wherein said locating collar has first and second thrust surfaces such that said first thrust surface inhibits axial movement of said first bushing relative to said center section in a first direction and said second thrust surface inhibits axial movement of said first bushing in a second direction relative to said center section.
 7. The stabilizer bar assembly of claim 5 further including a second locating collar extending outwardly from said tubular member and which is laterally spaced relative to said first locating collar, and wherein said first bushing is disposed between said first and second locating collars such that said first locating collar inhibits axial movement of said first bushing relative to said center section in a first direction and said second locating collar inhibits axial movement of said first bushing relative to said center section in a second directions.
 8. The stabilizer bar assembly of claim 7 wherein said first and second locating collars are formed at opposite ends of said tubular member, and wherein a first end surface of said first bushing engages said first locating collar and a second end surface of said first bushing engages said second locating collar.
 9. The stabilizer bar assembly of claim 1 wherein said first bushing has a center aperture, and wherein at least one of said center aperture, said locating collar and said center section is formed with a non-circular cross section such that said first bushing acts as a torsion spring to resist rotation of said center section.
 10. A stabilizer bar assembly, comprising: a bar having a center section and first and second end sections extending from opposite ends of said center section; an intermediate bushing coupled to said center section at a first location and having a tubular member surrounding a portion of said center section and a locating collar extending outwardly from said tubular member; a first bushing disposed over said tubular member such that said locating collar limits bi-directional axial movement of said first bushing relative to said center section; and a second bushing disposed for axial sliding movement on said center section toward a second location.
 11. The stabilizer bar assembly of claim 10 wherein said locating collar has first and second thrust surfaces, and wherein said first bushing surrounds said locating collar such that said first thrust surface inhibits axial movement of said first bushing in a first direction and said second thrust surface inhibits axial movement of said first bushing in a second direction.
 12. The stabilizer bar assembly of claim 11 wherein said first bushing encloses said locating collar and has an inner surface engaging an outer surface of said tubular member.
 13. The stabilizer bar assembly of claim 10 wherein said intermediate bushing further includes a second locating collar extending outwardly from said tubular member and which is laterally spaced relative to said first locating collar.
 14. The stabilizer bar assembly of claim 13 wherein said first bushing is disposed between said first and second locating collars such that said first locating collar inhibits axial movement of said first bushing in a first direction and said second locating collar inhibits axial movement of said first bushing in a second direction.
 15. The stabilizer bar assembly of claim 14 wherein said first and second locating collars are formed at opposite ends of said tubular member, and wherein a first end surface of said first bushing engages said first locating collar and a second end surface of said first bushing engages said second locating collar.
 16. The stabilizer bar assembly of claim 13 wherein said first bushing surrounds and encloses at least one of said first and second locating collars.
 17. The stabilizer bar assembly of claim 10 wherein said intermediate bushing is molded onto said center section at said first location.
 18. The stabilizer bar assembly of claim 10 wherein said first bushing has a center aperture, and wherein at least one of said center aperture, said locating collar, said tubular member and said center section is formed with a non-circular cross section such that said first bushing acts as a torsion spring to resist rotation of said center section.
 19. A stabilizer bar assembly comprising: a bar having a center section and first and second end sections disposed on opposite sides of said center section; a locator coupled to said center section at a first location; a first bushing disposed over said locator such that said locator limits bi-directional axial movement of said first bushing relative to said center section; and a second bushing disposed for axially sliding movement on said center section relative to said first bushing toward a second location.
 20. The stabilizer bar assembly of claim 19 wherein said locator is a locating collar.
 21. The stabilizer bar assembly of claim 20 wherein said locating collar is fixed to said center section at said first location and has first and second thrust surfaces, and wherein said first bushing surrounds said locating collar such that said first thrust surface inhibits axial movement of said first bushing in a first direction along said center section and said second thrust surface inhibits axial movement of said first bushing in a second direction along said center section.
 22. The stabilizer bar assembly of claim 21 wherein said first bushing encloses said locating collar and has an inner surface engaging an outer surface of said center section.
 23. The stabilizer bar assembly of claim 20 wherein said locating collar extends outwardly from a tubular member that is coupled to said center section at said first position, and wherein said first bushing surrounds said tubular member.
 24. The stabilizer bar assembly of claim 23 wherein said locating collar has first and second thrust surfaces such that said first thrust surface inhibits axial movement of said first bushing relative to said center section in a first direction and said second thrust surface inhibits axial movement of said first bushing in a second direction relative to said center section.
 25. The stabilizer bar assembly of claim 23 further including a second locating collar extending outwardly from said tubular member and which is laterally spaced relative to said first locating collar, and wherein said first bushing is disposed between said first and second locating collars such that said first locating collar inhibits axial movement of said first bushing relative to said center section in a first direction and said second locating collar inhibits axial movement of said first bushing relative to said center section in a second directions.
 26. The stabilizer bar assembly of claim 25 wherein said first and second locating collars are formed at opposite ends of said tubular member, and wherein a first end surface of said first bushing engages said first locating collar and a second end surface of said first bushing engages said second locating collar. 